ES3014027T3 - Distributed production method - Google Patents

Abstract

A distributed light-guided processing method includes obtaining an order (302) from a requester (404) for at least one finished product (374). Raw components (314) are supplied to at least one selected remote processing location (316). The selected remote processing location (316) includes a light-guidance system (310). Work instructions (344) are provided to the selected remote processing location (316), where these instructions (344) allow the light-guidance system (310) to guide the construction of the finished product (374). The finished product (374) is processed using at least the raw components (314), the work instructions (344), and the light-guidance system (310). The finished product (374) is shipped from the selected remote processing location (316) after processing is complete. (Automatic translation with Google Translate, no legal value)

Description

DESCRIPTION

Distributed production method

FIELD OF INVENTION

The present invention is directed to a method for performing process operations, and in particular a method for distributing industrial operations such as manufacturing, assembly, inspection, or kitting of parts to remote light-guided processing locations wherein a virtual production coordinator selects a remote processing location from a plurality of processing locations via the Internet and provides work instructions to the light-guided system at the selected processing location.

BACKGROUND OF THE INVENTION

Light-guided systems use augmented reality to visually and audibly guide users through manual assembly, inspection, kitting, or training processes while recording and transmitting a wide variety of analyses. U.S. Patent 2017/255186 A1 describes a light-guided system for providing visual indicators to an operator performing operational steps. The guidance system includes a controller and directional light devices and is operable, in response to operation information or characteristic or identification information associated with a sensed workpiece, to selectively provide indicator lights to guide the operator in part selection and/or assembly. The system is also operable in response to confirmation signals provided to the control module to verify completion of a particular operation or task. Employees in factories, hospitals, and many other work environments typically travel to a physical place of employment to perform their jobs. Such a practice increases expenses and time spent by users and increases traffic congestion and emissions.

SUMMARY OF THE INVENTION

The present invention provides a distributed processing system and method for distributing assembly, inspection, part preparation, and/or forming requirements (hereinafter, distributed processing) of multiple products to at least one remote production location, which today typically occurs in a factory, warehouse, hospital, and/or other centralized work location. Each remote production location includes at least one light-guided workstation configured to guide a manufacturing process. The invention is set forth in the appended set of claims.

In accordance with one aspect of the present invention, a method for distributing processing includes a virtual production coordinator obtaining at least one order for at least one finished product from a customer via a computing device. The order may be obtained via the Internet by a cloud computing service. The production coordinator selects via the Internet at least one remote processing location from a plurality of processing locations to provide a product for the order, each processing location including a light-guided system including a guidance system computer and a light projector, the selection being based on the production coordinator maintaining information regarding the capacity, availability, and/or authorization of the remote processing locations to perform particular operations. Raw components are provided to at least one remote location, each remote location including a light-guided system. The method includes providing work instructions via the Internet to the light-guide system at each selected remote location, and manufacturing, using at least the raw components, the work instructions, and the light-guide system, at least one finished product. Work instructions can be provided to the light guidance system via the internet using a cloud service. The finished product is then delivered to the customer. Data and analytics can be collected and analyzed at each step to increase quality and/or productivity, or for training purposes.

In accordance with another aspect of the present invention, a distributed processing or manufacturing system includes a plurality of remote production locations, a cloud computing service, and a virtual production coordinator. Each of the remote production locations includes at least one light-guided workstation. The cloud computing service is configured to receive orders for finished goods from customers and send the orders and associated work instructions to the light-guided system of at least one of the plurality of remote production locations. The production coordinator is configured to coordinate, via the cloud computing service, the sending of the orders and work instructions to the plurality of remote production locations, and is further configured to coordinate the delivery of raw components to the plurality of remote production locations. Each light-guided workstation is configured to guide a manufacturing process using at least the raw components and the work instructions to produce finished goods.

In one aspect of the present invention, the requested product includes at least one assembled product, a product inspection, a product kit, and product manufacturing training. Each of the multiple remote production locations is also configured to review the finished products for errors and to report errors to the production coordinator.

In another aspect of the present invention, the production coordinator is configured to coordinate the delivery of finished products to customers. The production coordinator is further configured to coordinate the delivery of raw components and work instructions based on orders received from customers. The production coordinator is also configured to send a first order to a first remote production location of the plurality of remote production locations based at least in part on a quantity of raw components already present at the first remote production location.

In another aspect of the present invention, the process comprises inspection such that a completed product is an inspected product. The raw components comprise any of an individual article, assemblies or articles, and subassemblies provided for inspection.

These and other objects, advantages, purposes and features of this invention will become apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an operational guidance system constructed as an assembly guidance system at a workstation;

FIGS. 1A-1L illustrate exemplary images that may be projected by the light sources of the assembly guidance system of FIG. 1;

FIG. 2 is a schematic illustration of the operation of the assembly guidance system of FIG. 1; FIG. 3 is a block diagram illustrating an exemplary distributed light-guided production system in accordance with the present invention;

FIG. 4 is a block diagram illustrating an exemplary distributed light-guided production system in accordance with the present invention; and

FIG. 5 is a flow diagram illustrating the steps of a method for distributed manufacturing in accordance with the present invention.

DESCRIPTION OF PREFERRED IMPLEMENTATIONS

Referring now to the drawings and the illustrative embodiments depicted therein, a method for distributed light-guided manufacturing includes obtaining, from a customer, at least one order for completing at least one finished product. As shown in FIG. 3, an order 302 may be provided to a particular remote producer or remote location, hereinafter referred to as a remote production or processing location 316, via the cloud computing service 312 based on confirmation from that remote production location that it is available for an order 302 at that time. Raw materials or components 314 may be ordered via the cloud computing service 312. Raw components 314 are provided to the at least one remote production location 316. The components 314 may be provided, via delivery, from a factory, store, warehouse, or the like. Delivery may be accomplished by any manner of transportation, including, but not limited to, automobile, truck, or drone. Raw components 314 may be delivered prior to an order being placed, as such, the remote production location 316 is supplied with inventory to complete a variety of different products. Alternatively, the delivery of raw components 314 may be in response to the order being placed 302 or the order being assigned 302 to a remote production location 316. Excess raw material or components 314 at a remote production location 316 may also be returned to relieve accumulated inventory at the remote production location 316. This allows for the precise delivery of the exact type and quantity of raw components needed to complete the order. As discussed herein, the order 302 may include one or more of an assembly, inspection, kitting, and training order.

Each remote production location 316 includes a light guide system, or light guide workstation 310, which in the illustrated embodiment comprises a LIGHT GUIDE SYSTEM PRO or STRATUS LIGHT GUIDE SYSTEM provided by OPS Solutions LlC of Wixom, Michigan. Alternatively, the remote production locations 316 may utilize a combination of devices such as a computer and projector, a phone and projector, a Chromebit and projector, or an Intel Compute Stick. Such devices may be integrated with a webcam or other device including, but not limited to, an Orbbec Persee camera, Microsoft Kinect, or Basler TOF 3D.

The methods and systems of the present invention provide distributed light-guided production via a light-guided workstation, such as the operational guidance system disclosed in U.S. Patent No.

No. 7,515,981, issued April 7, 2009 (hereinafter the '981 patent). As discussed herein, light-guided workstations 310 are typically an "augmented reality" tool that includes a projector to display images at the remote production location 316, and guides and directs the user through audio and visual prompts. This system helps reduce errors, improve manufacturing, assembly, and inspection processes, and decrease the amount of training required for users.

Referring to FIGS. 1-2, the '981 patent discloses a light guided system or light guided workstation 10 in connection with providing visual indicators to an operator 12 performing one or more actions (e.g., assembly, inspection, kitting, and forming) on a workpiece 14 at a workstation 16 of an assembly line 18. The illustrated guidance system 10 includes a controller or control module 20, two directional light devices 22, 24, a sensing apparatus 26, and a confirmation module or device or element 28, shown as a foot pedal 30. The guidance system 10 includes a component location 32, which is illustrated as a parts bin 34, a display device 36, and a tool 38, and a tool holder 40.

The guidance system 10 may operate, in response to operational information or characteristic or identifying information associated with the workpiece 14 detected by the sensor apparatus 26, to selectively provide indicator lights 46, 52 to guide an operator in selecting and/or assembling parts to the workpiece 14, with the indicator lights 46, 52 directed and/or provided based upon, at least in part, the operational information detected by the sensor apparatus 26. The guidance system 10 is also operable, or alternatively, in response to one or more confirmation signals, such as confirmation signals 48, 56 and/or 84 of FIG. 2 which are described below, which may be manually or automatically provided to the control module 20 to verify completion of a particular operation or task. The system 10 may further be operated via the display device 36 to provide and transmit information to the operator 12, such as a list of steps to be completed, work instructions, images of a workpiece, videos, and/or warnings about a skipped or incorrectly performed assembly step.

Referring to FIGS. 1 and 2, as the workpiece 14 initially enters the workstation 16, the sensing apparatus 26 detects an operational or characteristic information or identification information associated with the workpiece 14, such as, for example, the presence and/or type of workpiece 14 present at the workstation 16. Responsive to the detection by the sensing apparatus 26, a first input signal 42 is communicated or transmitted to the control module 20, and based upon the detected or identified workpiece 14 that the operator 12 is or will be working on, the control module 20 communicates or transmits a command signal 44 (FIG. 2) to the directional light device 22 to project an indicator light 46 at a location on the parts bin 34 to guide the operator 12 to a part required for a particular step in the assembly action. After the proper part is selected, a confirmation signal 48 (FIG. 2) is sent to the control module 20, the control module 20 then transmits a command signal 50 (FIG. 2) to the directional light device 24 to project the indicator light 52 to indicate the location of the operating step 54 on the workpiece 14 where the selected component is to be installed. Upon completion of a particular operating step, the operator 12 may actuate the foot pedal 30, or other device, to transmit a confirmation signal 56 (FIG. 2) to the control module 20 verifying that the operating step has been completed. The control module 20 may then send another command signal 49, 50 to one of the directional light devices 22, 24 to indicate the next step of the operation, or it may indicate that operations are complete for that part if all of the required selection and assembly steps have been properly completed. The system may additionally or alternatively include sensors to automatically detect that an operational step has been completed, which may involve detecting that an operational step has been successfully completed. This may include, for example, cameras or other sensors to detect the completion of an operation.

The guidance system 10 is capable of providing visual indicators to the operator 12 that are specific to a particular workpiece 14, as such, for example, multiple different styles or types of workpieces requiring different components or parts may be processed at the workstation 16 with a significant reduction in the risk of assembly errors occurring. The assembly guidance system 10 thus provides a cost effective and accurate method for guiding an operator 12 through a series of tasks and provides confirmation that the tasks have been fully performed and completed in the correct order. The control module 20 may also be utilized to monitor cycle times of individual operating steps and combined operations performed at the workstation 16 for reporting system productivity, or the like.

The guidance system 10 is shown in FIG. 1 in connection with workstation 16, where the workstation 16 is part of an assembly line 18 that includes additional workstations 58, 60 for performing subsequent operations. Additional assembly guidance systems may be included at the other workstations of the assembly line, or a single assembly guidance system may be used to assist in operations at more than one workstation.

As noted, the sensor apparatus 26 has the function of sensing operational or characteristic information or identification information associated with the workpiece 14, such as the presence and/or type of the workpiece 14 located at the workstation 16, and may be constructed as one or more of a number of known sensors such as, for example, a proximity switch, a light curtain, a photoelectric eye, a radio frequency identification device, a bar code reader, or the like. When constructed as a radio frequency identification device or a bar code reader, a readable label or bar code may be placed on the workpiece or on the structure upon which the workpiece is supported as it moves along the assembly line. The label or bar code may contain information about the type of workpiece at the workstation 16, such as the model of the workpiece, measurements related to the workpiece, or the type of components needed. A scanner or reader may be hand-held by the operator or mounted on the assembly line, the scanner being able to read information from the label or bar code as the workpiece 14 enters the workstation 16. Alternatively, a sensing apparatus 26 may comprise a vision system configured to detect an identifiable feature or identifying information associated with a workpiece 14. The guidance system 10 may alternatively or sequentially be activated for subsequent operations by non-automated signals. For example, an operator 12 may manually enter a part type into the guidance system 10, press a palm button, press a touch screen, or simply initiate operations or pre-operations on a part.

The type of part present at a particular workstation need not be determined using a bar code or radio frequency system. For example, and as is known in the art, standard binary type sensors or cameras may be used to detect distinctive geometric features of a workpiece or the structure upon which it is placed in order to “identify” the workpiece 14. Furthermore, a guidance system 10 could be constructed wherein an operator 12 uses a handheld scanner to scan a bar code label affixed to the workpiece or the structure supporting the workpiece 14 rather than the scanner being mounted directly on the assembly line. The sensor apparatus 26 may also be used to detect the relative orientation of a workpiece 14 with respect to the workstation 16, with the control module adapted to receive the positional information and accordingly provide tailored command signals to the directional light devices such that the projected indicator lights accurately illuminate the locations of the desired operational steps. Furthermore, the presence of a part at a workstation 16 may be supplied to the operational guidance system by an input signal manually activated by an operator, such as a touch screen, a palm button, or the like.

The control module 20, in the illustrated embodiment, is a computer controller device and, as indicated, is adapted to receive and send various signals to monitor and guide assembly actions at the work station 16. The control module 20 may be constructed as a desktop or laptop PC, a PLC or the like, or it may be a networked computer system that can be used to control and monitor other aspects of the assembly line and work stations.

As indicated above, the control module 20 is adapted to receive a first input signal 42 regarding workpiece identification information 14 present at the workstation 16. In the illustrated embodiment of FIG. 1, the first input signal 42 is transmitted to the control module 20 directly from the sensor apparatus 26 along the communication link 62, where the link 62 is a computer cable, a fiber optic line or the like. Alternatively, however, a first input signal 42 may be transmitted to a networked computer system, and in response to the first input signal 42, the network system may provide the control module 20 with identifying information relating to the workpiece 14 present at the workstation 16. The identifying information, as indicated above, may simply indicate the presence of a workpiece at the workstation and/or may include information relating to the type of workpiece 14 at the workstation 16, such as a model of the workpiece, measurements relating to the workpiece, or the type of components needed. Optionally, a sensor apparatus 26 and a control module 20 may alternatively be constructed to wirelessly transmit and receive identifying information.

In response to the first received input signal, the control module 20 sends command signals 44, 50 to the directional light devices 22, 24 along the link 64 to provide visual indicators to the operator 12, as described in more detail below, and the command signals 44, 50 are communicated based, at least in part, on the first input signal 42. In the illustrated embodiment, two substantially similar directional light devices 22, 24 are provided at the workstation 16 and respond to the command signals 44, 50 from the control module 20. The directional light device 22 is used to project the indicator lights 46 at the location of the component 32, while the other directional light device 24 is used to project the indicator lights 52 at the locations of the operational steps 54 on the workpiece 14. Each directional light device 22, 24 includes a light source 66 for projecting indicator lights 46, 52, with the directional light devices 22, 24 constructed such that the indicator lights 46, 52 may be selectively and movably positioned to direct the indicator light 46, 52 at pre-set locations. The light sources 66 may also be constructed to provide an indicator light beam of selectively adjustable brightness to compensate for ambient surroundings and/or the distance from the light source to the selected point of impact. Although the light sources 66 are illustrated in FIG. 1 as projecting a single beam of indicator light, it should also be appreciated that the light sources 66 may be constructed to simultaneously project two or more beams such that, for example, multiple parts may be indicated for selection from location 32 by the operator 12 or multiple assembly locations may be indicated.

The light sources 66 can be constructed as laser light sources capable of projecting a focused, coherent beam of light at a desired location. The laser light sources can preferably be Class 3 lasers or lower for use within a visual environment for operators. Alternatively, light sources other than lasers can be used and still operate as intended, such as standard projectors, incandescent lights, light-emitting diodes (LEDs), or the like.

The light sources 66 may be constructed such that they produce different colored light from each other to further provide visual cues to the operator 12 while working at the workstation 16. Furthermore, the light sources may be adapted to project animated images or videos onto a surface, such as the surface of the workpiece 14, the assembly line 18, or a workstation 16, 58, 60. The projected animated images or videos may be, for example, a training video, and may be in an . mpeg, . wmv, or other similar file format provided by, or stored in, for example, a control module of an operational guidance system.

Referring to FIGS. 1A-1L, the directional light devices 22, 24 may also include known optical effect devices for fanning or shaping or configuring the projected indicator lights 46, 52 produced by the light sources 66 into a desirable shape, pattern, or configuration at the point or location where the indicator light 46, 52 strikes the location of the component 32 or the location of the operational step 54. For example, the indicator light may initially be projected as a geometric shape (FIGS. 1J-1L), such as a circle, around a particular location, to quickly attract the operator's attention, and then focused to a smaller diameter spot or circle at the specific location. The indicator light may also be projected to produce alphanumeric characters, as shown in FIGS. 1A-1L, flash, and/or produce rotating images. For example, sequential numbers may be projected where each number indicates a step in the assembly action being performed by the operator at the workstation, or part numbers or textual information may be projected to provide written guidance to the operator. Indicator lights projected by light sources, as described in more detail below, may further be configured to display videos or images or animation on the surface upon which the indicator light is incident. The configured images form a type of graphical display or visual display (VFD) displayed by an indicator light, such as indicator light 46 or 52, when projected onto a surface, with FIGS. 1A-1L depicting examples of graphical displays or VFDs.

As noted above, the indicator lights 46, 52 may be projected at the location of the components 32 or at the locations of the operating steps 54 associated with the workpiece 14. The component location 32 is exemplified as a parts bin 34 having multiple storage locations 70 for holding various parts required in the assembly of the workpieces 14. As shown, the directional light device 22 is functional to selectively project an indicator light 46 at discrete storage locations 70 of the parts bin 34 in response to the command signal 44 to indicate to the operator 12 the selection of the part.

RFID tags, or the like, may also be used to provide information to the control module 20. For example, an RFID tag located on a parts container 34 may be used in connection with the guidance system 10 to monitor the presence and/or proper location of the parts container 34. In the event that the guidance system 10 detects, for example by the control module 20, the absence of the parts container 34, an error message may be displayed, for example, by the display device 36, or projected by a light device 22, 24, or an audible warning message may be transmitted.

In the illustrated embodiment of FIG. 1 , the storage locations 70 of the parts container 34 include sensing devices 72 that are adapted to detect or sense when a component has been removed from a particular storage location 70. The sensing devices 72 may be of known construction and are selected based on a particular application, taking into consideration the types or models of workpieces 14 and parts to be assembled. The sensing devices 72, for example, may comprise light curtains, proximity sensors, electronic mats, such as pressure-sensitive mats, machine vision systems, or the like.

The sensing devices 72 may transmit a confirmation signal 48 to the control module 20 via link 74 when the operator 12 selects a part from a particular storage location 70, and the control module 20 may determine whether or not the operator 12 has selected the correct part when prompted. In response to the confirmation signal 48, if the operator 12 has selected the correct part as indicated by the indicator light 46, the control module 20 may turn off the indicator light 46 projecting from the directional light device 22 at the storage location 70 and transmit a subsequent command signal 50 to the directional light device 24 to project an indicator light 52 to the operating step location 54 on the workpiece 14 where the just-selected part is to be assembled. However, if the control module 20 determines that an incorrect part has been selected compared to what should have been selected as indicated by the indicator light 46, the control module 20 will not provide the subsequent command signal 50. In addition, the control module 20 may be constructed to provide a visual or audible signal to the operator 12 when an incorrect part has been selected from a storage location 70.

Although not illustrated, the parts container 34 may additionally employ a known pick-to-light system whereby each storage location includes an illumination device, such as an LED or the like, illuminated above to indicate to the operator the proper storage location from which a part is to be selected. When the guidance system 10 includes a pick-to-light system, the directional light device 24 used to project an indicator light 46 onto a component location 32 may optionally be excluded.

As noted above, the guidance system 10 includes a confirmation module 28, which in the illustrated embodiment is a foot pedal 30. The confirmation module 28 is constructed to transmit a confirmation signal 56 along link 76 to the control module 20 to indicate that the operational step indicated by the directional light device 22 or 24 has been completed. To transmit the confirmation signal 56, the operator 12 simply depresses the foot pedal 30 upon completion of the directed activity. The confirmation signal 56 transmitted by the foot pedal 30 then activates the control module 20 to selectively transmit another command signal 44, 50 to provide guidance to the operator 12 regarding the subsequent operational step to be performed by the operator 12 at the workstation 16 in accordance with the workpiece 14. For example, the guidance system 10 may cause an indicator light 46 to be projected onto a storage location 70 for the next required workpiece. Alternatively, the control module 20 may provide a command signal that releases the workpiece to the next workstation 58 if all operating steps at the current workstation 16 have been completed.

Although illustrated as a foot pedal 30, it should be understood that numerous alternative confirmation modules 28 may be utilized. For example, the confirmation module 28 may be constructed as a pressure-sensitive mat, push button, toggle switch, palm button, light curtain, touch screen, touchpad, part presence sensor, or the like, which is constructed to be pressed, toggled, or otherwise activated by a manual action of the operator 12. A sound-activated signal may alternatively be employed, such as a voice command, to provide a confirmation signal. The confirmation module 28 may also be constructed as a wireless transmitter, thereby eliminating the need for a physical link. Furthermore, the guidance system 10 may be adapted to receive and/or respond to other confirmation signals and/or sources as additional technologies become available.

In addition, a confirmation module or device or element can be constructed to automatically detect when an operator has completed a manual step. For example, a confirmation module can be constructed as a vision system capable of detecting the presence or absence of a component at that location, such as by processing an image captured by a pixelated imaging device, as is known in the art. Alternatively, for example, the confirmation module can be constructed as a proximity sensor, photo eye, light curtain, or the like, constructed to automatically detect the presence or absence of a part in the assembly to the workpiece. In addition, a confirmation signal can be transmitted by an automated tool or measuring device, such as a torque gun, weight scale, or other type of measuring device, as described in more detail below. In this case, the automated tool or measuring device can function as a confirmation module. The indicator light projected by a light source of an operational guidance system may also be used to provide a confirmation signal when, for example, a sensor in the light source or another part of the operational guidance system is employed to detect the reflection of an indicator light from a part or component requiring verification. The light sources may also be used as a "light curtain" by projecting onto a particular location or part container, or the like, with a sensor adapted to detect that an operator has correctly selected from that location.

It should also be appreciated that operational information could be transmitted to the controller 20 from a remote signal. For example, in the case of a kitting operation, a requisition may be transmitted to a workstation 16 from a central processing location, such as a computer system or the like, and a signal transmitted to the workstation 16 regarding, for example, which parts to gather and/or assemble. In this case, the workpiece of the operation may comprise a collection of assembled parts within a parts rack.

Although not illustrated, the guidance system 10 may also incorporate known ultrasonic, electromagnetic, and/or similar technology used to confirm, for example, that a tool is positioned on the proper bolt or nut in an assembly operation. Such technology is configured to send and receive ultrasonic frequencies, with the spatial location of a sent or received signal being monitored to confirm that an operation is performed in a proper location. Thus, the guidance system 10 may be configured to utilize both light sources and ultrasonic, electromagnetic, and/or similar technology to confirm assembly or other manual process steps.

The guidance system 10 also includes a display device 36 that can receive display signals 78 (FIG. 2) along link 80 (FIG. 1) from the control module 20 and transmit information to the operator 12. The display device 36 may be a television, LCD, LED, or other type of display mechanism. The display device 36 may be used to present information to the operator 12, such as, for example, sequential steps to be performed, work instructions associated with the workstation 16, images of a workpiece 14 properly clamped with the part to be assembled, information regarding a skipped or incorrectly performed assembly step, or the like. In the case of sequential steps, the display device 36 may be configured to highlight the current step under consideration and/or provide an indication that previous steps have been completed. The display device 36 may be constructed as a touch screen device adapted to be pressed by an operator to provide a confirmation signal regarding the completion of a particular step. The inclusion of such a touch screen device may also provide the ability to prompt or guide an operator through certain operational or assembly steps that do not require guidance via indicator light signals. The display device may also be used to display or provide instructional videos, display running cycle times, desirable cycle times and/or alerts, or the like. In the case of a touch screen, upon an operator touching a particular location or tab on the screen, a video or image may be displayed on the display screen, or other display screen, or may initiate the projection of an indicator light or video. The guidance system 10 also includes a display device 36 that can receive display signals 78 (FIG. 2) along link 80 (FIG. 1) from the control module 20 and transmit information to the operator 12. The display device 36 may be a television, LCD, LED, or other type of display mechanism. The display device 36 may be used to present information to the operator 12, such as, for example, sequential steps to be performed, work instructions associated with the workstation 16, images of a workpiece 14 properly clamped with the part to be assembled, information regarding a skipped or incorrectly performed assembly step, or the like. In the case of sequential steps, the display device 36 may be configured to highlight the current step under consideration and/or provide an indication that previous steps have been completed. The display device 36 may be constructed as a touch screen device adapted to be pressed by an operator to provide a confirmation signal regarding the completion of a particular step. The inclusion of such a touch screen device may also provide the ability to prompt or guide an operator through certain operational or assembly steps that do not require guidance via indicator light signals. The display device may also be used to display or provide instructional videos, display running cycle times, desirable cycle times and/or alerts, or the like. In the case of a touch screen, upon an operator touching a particular location or tab on the screen, a video or image may be displayed on the display screen, or other display screen, or may initiate the projection of an indicator light or video.

Optionally, the guidance system 10 may be used in connection with a tool 38 and a tool holder 40. The tool 38 may comprise, for example, a manual tool, such as a wrench, a torque wrench, pliers, a screwdriver, or the like, or it may be an automated tool, such as an electric screwdriver, an air gun, an electric torque wrench, or the like. The tool 38 may otherwise be a manual or automated measuring device, such as calipers, a gauge block, feeler gauges, air gauge device, or the like. The tool holder 40 is provided to provide a storage location for the tool 38 when the tool 38 is not in use. The directional light devices 22, 24 may project an indicator light onto the tool 38 and/or the tool holder 40 in response to a command signal when the tool 38 is required to complete a pending operational step, such as in a manner similar to that described above with respect to the storage locations 70 of the parts container 34 and the operation step locations 54 on the workpiece 14. The tool holder 40 may include a sensor and thus be integrated with the guidance system 10 for detecting when the tool 38 is positioned within or extracted from the tool holder 40, where the sensor may be a photoeye, a proximity switch, a light curtain, or the like.

Although not illustrated, the guidance system 10 may utilize an automated gauge or tool that is electrically linked to a control module such that the control module is capable of monitoring both utilization of the tool and an operable parameter associated with the tool. For example, if a tool is constructed as a torque wrench, the control module may be constructed to monitor the fastener torque obtained by the torque wrench and to compare the value to a preprogrammed or predetermined threshold value before transmitting a subsequent command signal. Thus, the control may be operable to transmit the subsequent command signal only after the torque wrench has applied the desired or appropriate torque. Similarly, if the tool is constructed as a measuring device, such as digital calipers, the control module may be constructed to receive a measurement value, and may compare the measurement value to a threshold measurement value, and may communicate or transmit the subsequent command signal when the measurement value is at or near the threshold measurement value.

The control module 20 is illustrated as transmitting a command signal 44a to the directional light device 22, which in response to the command signal 44a, projects the indicator light 46a onto the location 70a of the parts container 34. Upon receiving the confirmation signal 48a from the detection device 72 signifying that the proper part was selected, the control module 20 then terminates the projection of the indicator light 46a and transmits the command signal 50a to the directional light device 24 such that the indicator light 52a is projected at the operational step location 54a on the workpiece 14 to direct the operator 12 as to the proper assembly point for the selected part. The operator 12 then activates the pedal 30 (or other confirmation device), which transmits the confirmation signal 56a to the control module 20 and the above process is repeated for the indicator lights 46b, 52b, 46c, 52c, the storage locations 70b, 70c, and the operational passage locations 54b, 54c.

As illustrated in FIGS. 3 and 4, in the light-guided systems or light-guided workstations of the present invention, it is appreciated that there may be any number of remote processing locations 316a, 316b, each with one or more light-guided workstations 310a, 310b, and each provided with raw components 314 from a factory, warehouse, hospital, or restaurant, etc., or components for inspection may be provided to the remote processing locations 316a, 316b. The raw components 314 may be components provided for such inspection, where such components provided for inspection include complete assemblies, subassemblies, and combinations thereof.

The remote processing locations 316a, 316b may be located anywhere capable of supporting a light-guided workstation 310, such as, for example, a user's home, garage, or other suitable property, or even a contract processing location. The remote processing locations 316 may also include one or more light-guided workstations 310. The production coordinator 402, via the cloud computing service 312, may select an appropriate number of remote processing locations 316a, 316b to ensure proper completion to satisfy the order. Alternatively, the production coordinator 402 may select an order 302 from a list of available orders (via the cloud computing service 312). The method allows for flexible scheduling and workloads by the operators of the light-guided workstations 310 (at the remote processing locations 316). As discussed above, light-guided workstations 310 are typically an “augmented reality” tool that includes a projector to display images at the remote processing location 316, and guide and direct the user/operator using audio and visual prompts. Such a system helps reduce errors, improve manufacturing, assembly, and inspection processes, and decrease the training required for users.

Each remote processing location 316a, 316b is provided with work instructions 344. These work instructions 344 are provided over the Internet from the cloud computing service 312. While instructions 344 for a wide variety of potential products may be provided prior to obtaining a request 310, ideally the work instructions 344 are provided in response to obtaining an order 302. These work instructions 344 are adapted to allow the light-guided systems/workstations 310 to instruct the user/operator 12 to complete the specific desired completed product 374. Using at least the raw components 314, the light-guided workstation 310, and the work instructions 344, at least one completed product 374 is completed by the user at the remote production location 316. Any defects detected during completion may be reported to the cloud computing service 312 (and the production coordinator 402) for appropriate analysis by other parties including, but not limited to, the original producer of the product, end customers 404, or data analytics firms for machine learning or artificial intelligence. The completed product 374 may then be delivered to the requesting customer 404 through any appropriate means. For example, a conventional delivery service may schedule a time to pick up completed products from remote processing location 316. Production coordinator 402 may schedule the delivery service when order 310 is assigned to remote processing location 316 based on the quantity and/or complexity of completed product 374. Delivery times may be optimized by choosing remote processing locations 316 that live close to the requesting end customer 404 to complete completed product 374 and either deliver the product themselves or use a local third-party carrier.

In this way, each user of the light-guided systems/workstations 310 can complete products without the need to travel to a typical employment location. Any number of products can be assembled, inspected, kitted, calibrated, or otherwise completed according to projected work instructions 344, including manufacturing products, hospitality products, textiles, and food. Perishable foods, such as sushi or meat, could be processed near the requested customers 404, thereby reducing their spoilage, or in isolated areas that typically do not have access to such products. Furthermore, this method allows for easily completing highly customized products or associated processes, such as a personalized birthday cake, custom floral arrangements, or even specialty pizzas.

FIGS. 4 and 5 also illustrate the lines of communication that exist between clients 402, production coordinator 402, remote production locations 316, raw component suppliers, and collection services via network connections to cloud computing service 312 (i.e., the Internet). Such communications are capable of confirming that orders 302 have been received, as well as confirming when those orders 302 have been completed (and the completed product 374 picked up for delivery to the requesting customer 402). Similarly, communications exist between the raw component suppliers and the remote processing locations 316 such that the raw component inventory 314 can be managed. This includes the shipping and receiving of orders for delivery of raw components 314, as well as managing the removal of excess inventory as needed. In addition to receiving orders 302 from customers 404 and passing those orders 302 (and necessary work instructions 344) to particular remote processing locations 316, the remote processing locations 316 are also configured to provide the production coordinator 402 with their individual status, order completion indications, as well as their individual availability. Similarly, delivery services are configured to receive pickup orders from the remote processing locations 316, as well as from the production coordinator 402 (via the cloud computing service 312). Delivery confirmation of the completed product 374 to the requesting customer 404 is also possible.

FIG. 5 illustrates an exemplary method for distributed processing. As illustrated in FIG. 5, in step 502, orders 302 are received from one or more requesting customers 404. The orders 302 may include one or more of product assembly, production inspection, kitting, and training to be processed. In step 504, the orders 302a, 302b are sent to a selected remote processing location 316a, 316b. The selection of a particular remote processing location 316 may be based on one or more criteria. For example, a remote processing location 316 may be selected because of the raw components 314 that are present at that remote production location 316. The remote production location 316 may be selected based on a cost to provide the completed product 374, as reported by that remote processing location 316. Other criteria may also be used to make such a selection.

In step 506, raw components 314 are provided to the selected remote processing location 316. These raw components 314 may be provided based on orders 302a, 302b submitted to the selected remote processing location 316a, 316b. In step 508, associated work instructions 344 are also provided to the selected remote processing location 316, such that the selected remote processing location 316a, 316b is capable of fulfilling orders 302a, 302b and producing the completed product(s) 374.

In step 510, the selected remote processing location 316 places and fulfills the order 302 to produce a completed product 374. As discussed herein, the order 302 is fulfilled utilizing one or more light guidance systems or workstations 310. In step 512, the completed product 374 is delivered to the customer 404. Also discussed herein, the completed product 374 may be delivered to the customer 404 in a variety of ways with the utilization of a scheduled delivery service or through a specific request for pickup and delivery of the completed product 374 to the customer 404. The completed product 374 may also be delivered as requested by the customer 404.

The method illustrated in FIG. 5 can also be adapted to repair or remanufacture already produced goods. Furthermore, it can be extended by using three-dimensional (3D) printers and collaborative robots. The collaborative robots can also be used to provide remote assistance. The light-guided system can include sensors for remote monitoring of the producer. Sensors such as heart rate sensors, blood pressure monitors, eye trackers, or accelerometers can be used to measure the remote producer's engagement, tension, attention, concentration, or other responses to work instructions or the product being manufactured.

Furthermore, the methods of the present invention may reduce employment costs for the user or operator 12, as a particular user may be able to spend less on fuel, car maintenance, daycare, etc. Furthermore, embodiments of the present invention allow for a flexible and balanced workforce that can easily complete products across a variety of conditions, geographic locations, and time zones. Each remote processing location 316 with one or more light-guided workstations 310 may be shared by a number of users or operators 12. For example, an exemplary remote processing location 316 could be located near a neighborhood, such that members of that neighborhood could make use of the remote processing location 316 (and associated light-guided workstations 310) at all hours of the day or with multiple users at once. Traffic congestion and emissions from traffic are thus reduced. Companies can realize additional cost savings through savings in their Cost of Goods Sold (COGS) and other expenses such as taxes, property purchases and/or leases, and reduced profit requirements. Furthermore, the results of this method can be used to confer educational credits, certifications, or other degrees that have lasting value to the remote producer.

The method also enables the capture of logistics data relating to the delivery of raw components and work instructions, and the completion of products. Such data can be analyzed to further improve quality, productivity, and training, and may include comprehensive video, audio, and sensor data from remote processing locations and light-guided systems. The method may include real-time analysis of the operation to better understand how a defective part was incorrectly completed. Data can only be transmitted in the event that a defective product reaches the requesting end customer.

Orders 302 from a customer 404 may be transmitted to a physical production coordinator 402 or a virtual production coordinator 402 through the use of artificial intelligence and/or machine learning, with the production coordinator 402 in turn coordinating processing across the remote processing locations 316. For example, the remote processing locations 316 may be registered by the production coordinator 402, with the production coordinator 402 maintaining information regarding the remote processing locations 316, such as the raw materials 314 present at the remote processing locations 316, the qualifications, capacity, availability, and/or authorization of the remote processing locations 316 to perform particular operations. The production coordinator 402 may in turn facilitate the supply of raw materials/components 314 to the remote processing locations 316, as well as the shipment of completed products 374 produced by the remote processing locations 316, where the shipment may involve receiving notifications from the remote processing locations 316 regarding the availability of completed products 374, dispatching transportation to retrieve the completed products 374, and delivering the completed products 374 to a customer, warehouse, or other location for further utilization or processing. The production coordinator 402 also includes a computing device configured to receive and transmit orders, such as via the Internet. In this manner, the production coordinator 402 may facilitate the receipt of orders 302 from a plurality of customers 404, including for numerous different goods and products to be completed (374). In addition, the customer 404 and/or the production coordinator 402 may post the availability of orders 302 to a plurality of remote processing locations 316, with the remote processing locations 316 bidding on the orders 302 such as with respect to cost, time, and number of completed products 374 that can be processed by a remote processing location 316.

Live remote assistance may be provided to the remote processing locations 316 via an integrated camera and audio system, an integrated projector, a telephone system, and the like. The assistance may be provided by the physical or virtual production coordinator 402, a WIKI, or by another remote support device and/or person. In addition, the remote processing locations 316 may update, optimize, and store work instructions for parts that require rework or improvements, or alternative steps may be discovered. For example, the remote processing locations 316 may find ways to reduce scrap, waste, byproducts, or other undesirable aspects of the process. The remote processing locations 316 may upload the updated work instructions 344 to the production coordinator 402 via the cloud computing service 312. These updated work instructions 344 could then be shared with other remote processing locations 316 or analyzed for further improvements. In this way, improvements and optimizations to the work instructions 344 could be distributed among all remote processing locations 316. The optimized work instructions 344 could then be implemented elsewhere, such as in a traditional factory. Similarly, the remote processing locations 316 could discover improvements or optimizations to the completed assembled products 374, and could share these improvements similarly.

Consequently, the method for distributed processing, utilizing the distributed light guidance systems 310 of the present invention, provides a means for users of light guidance workstations 310 at remote processing locations 316 to fulfill orders 302 by processing completed products 374 and then delivering the completed products 374 to a customer 404. A customer 404 provides an order 302 to a production coordinator 402 via a cloud computing service 312 and the production coordinator 402 facilitates delivery of unprocessed components 314 to selected remote processing locations 316 with light guidance workstations/system 310 and the ability to fulfill the orders 302. The production coordinator 402 also provides each remote processing location 316 with work instructions 344 for the specific completed product 374 (as requested by the particular order 302a,b). 302b). Using light-guided systems/workstations 310, work instructions 344, and raw components 314, completed products 374 are completed at each remote processing location 316. The completed products 374 are then delivered to the ordering customer 404. The method and system provide high quality, productivity, and training effectiveness while reducing part manufacturing costs, traffic congestion, and environmental emissions.

Claims (14)

1. A computer-implemented one distributive processing method, which comprises obtaining by a virtual production coordinator (402), from a plurality of requesters (404), by means of a computing device a plurality of orders (302) for products that need to be processed; maintaining information by means of the virtual production coordinator (402) on the possibility, availability and/or authorization to carry out particular operations for each remote processing location (316) of a plurality of remote processing locations (316); 1. A production coordinator (402) selecting via the Internet at least one of the remote processing locations (316) from the plurality of remote processing locations (316) to provide one or more than one product (374) for each of the orders (302) in which the product (374) requires to be processed, wherein each remote processing location (316) comprises a light guidance system (310) including a guidance system computer (20) and a light projector (22, 24), and wherein the selection by the production coordinator (402) is based on the capacity, availability and/or authorization of the remote processing locations (316) to perform certain operations; facilitating, by the virtual production coordinator (402), the provision of raw components (314) for transformation into the product (374) at the at least one selected remote processing location (316); providing, by the virtual production coordinator (402), work instructions (344) via the Internet to the light guidance system (310) of the at least one selected remote processing location (316), wherein the work instructions (344) enable the light guidance system (310) of the remote processing location (316) to guide an individual in transforming the raw components (314) into the product (374) by operational steps; processing by the individual the raw components (314) into the product (374) at the selected remote processing location (316) using the work instructions (344) and the light-guided system (310) of the selected remote processing location (316), where said processing includes projecting the operational steps with the light-guided system (310) of the selected remote processing location (316) to guide the individual to process the raw components (314) into the product (374); facilitating, via the virtual production coordinator (402), the shipment of the product (374) from the remote processing location (316) once processing is complete; and capturing, via the virtual production coordinator (402), logistics data relating to the delivery of the raw components (314) and work instructions (344), and the completion of the products (374) 2. The method of claim 1, further comprising analyzing data collected from at least the provision of raw components, the provision of work instructions, the processing of the at least one completed product, and the shipment of the completed product for the purpose of at least one of the following: increasing quality, increasing productivity, or training. 3. The method of claim 1, wherein obtaining the order further comprises obtaining the order over the Internet. 4. The method of claim 3, wherein a cloud computing service (312) obtains the order (302) from the requester (404) via the Internet. 5. The method of claim 4, further comprising reporting the defects during processing to the cloud computing service (312). 6. The method of claim 1, wherein a number of remote processing locations (312) are selected in correlation with a quantity of completed products (374) ordered. 7. The method of claim 1, further comprising selecting, at each remote processing location (316), a selected order (302) from a list of orders and wherein processing of the completed product (374) is responsive to the selection of an order (302). 8. The method of claim 7, wherein the raw components (314) and work instructions (344) are provided in response to selecting an order (302). 9. The method of claim 1, wherein the raw components (314) and work instructions (344) are provided in response to obtaining the order (302) from the requester (404). 10. The method of claim 1, wherein the selection of at least one remote processing location (316) is based on at least one of: a quantity of raw components already present at a particular remote processing location; and a cost estimate or cost quote provided by the particular remote processing location. 11. The method of claim 1, wherein the required processing of the at least one product (374) includes inspecting the at least one product (374), and wherein the raw components (314) comprise any of the assemblies and subassemblies provided for inspection. 12. The method of claim 1, wherein the work instructions (344) are adapted to allow the light guide system (310) to instruct the user to complete the desired specific completed product (374). 13. The method of claim 1, wherein the remote processing locations (316) comprise at least one of homes, garages, a convenient property, and a contract processing position. 14. A distributed processing system configured to perform the method of any of claims 1 to 13 comprising: a plurality of remote processing locations (316), each of which comprises at least one light-guided workstation (310); a cloud computing service (312) configured to receive orders (302) for completed products (374) from requesters (404) and send the orders (302) and associated work instructions (344) to at least one of the plurality of remote processing locations (316); a virtual production coordinator (402) configured to coordinate, via the cloud computing service (312), the sending of the orders (302) and work instructions (344) to the plurality of remote processing locations (316), and further configured to coordinate the delivery of raw components (314) to the plurality of remote processing locations (316); and wherein each light-guided workstation (310) is configured to guide a process using at least the raw components (314) and the work instructions (344) to process completed products (374).